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Headlight won't work.

This is a discussion on Headlight won't work. within the The ZX6R forums, part of the ZX6R Forum category; I've never been very good with electrical, but I've been trying to fix my headlight issue that just popped up the other week. I was ...

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Old 02-24-2012, 02:41 PM   #1
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Headlight won't work.

I've never been very good with electrical, but I've been trying to fix my headlight issue that just popped up the other week. I was riding my bike and everything was working just fine until I shut it off to visit someone for a minute, and when I came back out and started the bike, the headlight just wouldn't turn on. I had to ride the bike home, and just before I got there, it started to sputter and all the cluster lights started freaking out, then the bike died (battery was dead). Bulb is fine, and I've swapped it to be sure, junction box replaced (holds headlight relay), fuses are good, and I've replaced the battery too. Bike runs fine now, and all the other lights and electronics work. The only other thing I can think of is a short in the headlight wiring somewhere. You fellas have any ideas?
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Old 02-24-2012, 03:14 PM   #2
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Charging system is not charging and draining the battery
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Old 02-24-2012, 05:29 PM   #3
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Quote:
Originally Posted by whocanitBnow View Post
Charging system is not charging and draining the battery
Maybe, but it wouldn't explain the headlight problem. I replaced the battery and the headlight still doesn't work.
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Old 02-24-2012, 06:42 PM   #4
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I don't know about the 1999 but the rectifier/regulator sends power straight to the headlights on the 05/06 so I'd start there. Check your shop manuals diagram and follow the schematic. Also check your grounds.

Last edited by oKayH; 02-24-2012 at 07:31 PM.
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Old 02-24-2012, 06:54 PM   #5
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And now theres a recall on the motherfuckin rectifiers....I bet that they're all bad from 2005-2012

Kawasaki Recall
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Old 02-25-2012, 07:08 AM   #6
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Quote:
Originally Posted by oKayH View Post
I don't know about the 1999 but the rectifier/regulator sends power straight to the headlights on the 05/06 so I'd start there. Check your shop manuals diagram and follow the schematic. Also check your grounds.
Hmmm, didn't know that. Maybe it's the same on a 99.
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Old 02-25-2012, 07:30 AM   #7
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Enter your VIN here for recall info.

Welcome to Kawasaki.com

Nothing on mine yet. I know the 07 -08 are the same except paint color.

Last edited by Street Hawk; 02-25-2012 at 07:33 AM.
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Old 02-25-2012, 10:13 AM   #8
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Newest development:

For some reason, the light decided to work when I started it this morning while probing around with my multimeter. I'm assuming there was just a bad connection somewhere, but who knows.

I was cruising down the road after that for a test ride, and after about 10 mins of driving, the bike did the same thing as when it died about a week ago. All the lights on the cluster and gauges started freaking out and then the bike gave out. When I tried to start it again, I just got clicking, indicating a dead battery. The thing is, though, this is a new battery. For some reason the battery isn't being charged. Could the headlight and charging issue be related, or is this just a bad alternator and a stupid coincidence that my headlight was acting funny before? Other than the alternator, are there any other parts that could be suspect as far as charging issues go?
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Old 02-25-2012, 12:07 PM   #9
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U need a new stator...and new rectifier ...me thinks
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Old 02-25-2012, 12:42 PM   #10
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I know the 07 -08 are the same except paint color.
That, and the 07's are just plain cooler...
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Old 02-25-2012, 02:11 PM   #11
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Quote:
Originally Posted by ZX6RRECTION View Post
U need a new stator...and new rectifier ...me thinks
It has to be one or the other, right? The regulator/rectifier has 6 prongs on the connection to the wiring harness with 2 rows and 3 columns.
I tested ohms on upper left prong to each of the 3 bottom prongs in both directions and then the same thing for the upper right prong with each of the 3 bottom prongs (as the manual says). My readings were about 7 ohms in one direction, and then nothing in the other, for both tests. Does this mean a bad regulator/rectifier?
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Old 02-25-2012, 03:29 PM   #12
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I'm still basing this off the 05/06...

The rec/reg has two circuits in one device. On the rectifier side of things there are diodes. They block the flow of current in one direction while allowing it to flow in the other. If that is the set of prongs that you are testing then you will have that type of reading. As far as proper ohms...idk. I have a few hundred ohms on mine but yours could certainly be different....or shorting out internally. The regulator side for troubleshooting calls for some applied voltages and a load and other shit...

Have you also tested the stator for shorts and open coils and proper output voltages?
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Old 02-25-2012, 03:40 PM   #13
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Quote:
Originally Posted by oKayH View Post
I'm still basing this off the 05/06...

The rec/reg has two circuits in one device. On the rectifier side of things there are diodes. They block the flow of current in one direction while allowing it to flow in the other. If that is the set of prongs that you are testing then you will have that type of reading. As far as proper ohms...idk. I have a few hundred ohms on mine but yours could certainly be different....or shorting out internally. The regulator side for troubleshooting calls for some applied voltages and a load and other shit...

Have you also tested the stator for shorts and open coils and proper output voltages?
Don't really know how to test for a bad stator.
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Old 02-25-2012, 04:45 PM   #14
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Ahahaha, well, it looks like I might have found the problem! While taking apart the bike to get to the stator connection, I found that it had been sitting against the engine and HAD COMPLETELY MELTED! I Jimmy rigged my bike up after having hacked up the old connector with a dremel and just twisted the 3 wires together, individually, to give it a test and see what happened. My battery was almost completely dead and needed a jump, but once I jumped the battery and let it charge for a minute, the bike has continued to run normally. At first, the voltage readings at the battery terminals were pretty low (13.4V), but every time I check it in about 3 minute intervals, it keeps getting higher, indicating proper charging. At present, after about 10 minutes of idling, I'm reading 14 V at the battery terminals. It's still a little low, but it's getting there. I also noticed that my bike is revving up much, much quicker than it used to. If this was the problem, I can't believe it was something so stupid.
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Old 02-25-2012, 05:04 PM   #15
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One other thing I want to add, while testing voltage at the battery terminals while the bike was running, I was noticing that the voltage readings would drop to as low as 1V sometimes. Keep in mind that I have a fairly cheap multimeter that I bought at walmart, but is this indicative of spikes in voltage and a bad regulator/rectifier?
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